Foam filling member

ABSTRACT

A foam filling member that can hold a foam sheet in a looped shape stably, without increasing the number of components, to provide improved vibration suppression and sound insulation. The strip-like foam sheet is formed in a looped shape by bending round it, so that both end portions of the foam sheet are overlapped with each other in a thickness direction thereof to form an overlapped portion therein. Then, insertion shafts of a clip are inserted through the overlapped portion, so that the overlapped portion is held in sandwich relation between a base portion and a head portion to form a foam filling member. Then, a supporting portion of the fixing portion of the clip is inserted in a fixing hole of an inner panel and fixed to the inner panel. After the inner panel and an outer panel are welded, the foam filling member is foamed, cross-linked, and cured by heating in a drying line process at the baking finish, to thereby produce the foam, whereby the interior space of the pillar is filled up with the foam, leaving no space therein.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from Japanese Patent Appln. Nos.2004-348947 filed Dec. 1, 2004, 2004-351626 filed Dec. 3, 2004, and2005-299677 filed Oct. 14, 2005, the contents of which are hereinincorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a foam filling member for forming foamto be filled in a space of a structure.

2. Description of the Prior Art

It is generally known that foam is filled in a hollow structure, such asa pillar of a vehicle, for the purpose of ensuring vibration suppressionand sound insulation. A foam filling member is used for forming suchfoam. In use, the foam filling member is placed in an interior space ofthe hollow structure to be filled and is foamed by the application ofheat from outside to form the foam, so that the interior space is filledwith the foam thus formed.

For example JP Laid-open (Unexamined) Patent Publication No. 2003-63443proposes a hollow panel foam filling method wherein an unfoamed solidfoam filling member is placed in an interior filling area of the hollowpanel and then is foamed by the application of heat from outside,whereby the foam resulting from the foam formation is filled in theinterior filling area. In this document, the foam filling member is inthe form of a sheet-like base foam material which is elasticallydeformable into a rolled shape. The sheet-like base foam material isplaced in the interior filling area in the rolled state, so that it isheld in the interior filling area by the resilience resulting from theelastic deformation of the rolled base foam material and, then, theas-rolled sheet-like base foam material is foamed by the application ofheat, whereby the foam resulting from the foam formation of the basefoam material is filled in the interior filling area.

However, this foam filling method described in JP Laid-open (Unexamined)Patent Publication No. 2003-63443 has the disadvantage that since thesheet-like base foam material rolled is held in the interior fillingarea by the resilience resulting from the elastic deformation of therolled base foam material, the sheet-like base foam material is notstably kept in the rolled state due to its possible displacement and,resultantly, it cannot be filled in the interior filling area of thehollow panel reliably.

On the other hand, when the sheet-like base foam material is held by aclip and the like for the purpose of keeping the sheet-like base foammaterial in the rolled state stably, there is provided anotherdisadvantage that the number of components is increased and also thereis provided the additional disadvantage that since the clip is buried inthe foam, the effects of the foam of vibration suppression and soundinsulation are reduced.

Also, some hollow structures, such as, for example, pillars ofautomobiles, have two inner spaces (e.g. a space between a side frameouter and a center pillar reinforce and a space between the centerpillar reinforce and a center pillar inner) to be filled with theirrespective foams, as disclosed in JP Laid-open (Unexamined) PatentPublication No. Hei 11-99960.

The structure described by JP Laid-open (Unexamined) Patent PublicationNo. Hei 11-99960 requires that after the foam filling material is set inthe space between the side frame outer and the center pillar reinforce,the side frame outer and the center pillar reinforce are welded, andafter the foam filling material is set in the space between the centerpillar reinforce and the center pillar inner, the center pillarreinforce and the center pillar inner are welded. Thus, this structurerequires at least two or more workings for setting the foam fillingmaterial in the interior spaces of the hollow structure, making theassembling work cumbersome and complicated.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a foam fillingmember that can hold a foaming sheet in a looped shape stably, withoutincreasing the number of components, to provide improved vibrationsuppression and sound insulation.

It is another object of the present invention to provide a foam fillingmember that can facilitate the assembling work.

To accomplish the objects mentioned above, the present inventionprovides a foam filling member for forming foam to fill up a space of astructure, which comprises a foam sheet formed from foamable materialand formed in sheet form, and a fixing member for fixing the foam sheetin the space of the structure, wherein the foam sheet is formed in alooped shape so that its portions spaced apart from each other in alongitudinal direction of the foam sheet confront each other, andwherein the fixing member comprises a retaining portion for retainingthe portions of the foam sheet, and a fixing portion for fixing theportions of the foam sheet in the structure.

In this foam filling member, the fixing portion of the fixing member canfix the foam sheet in the space of structure, while the retainingportion of the fixing member can keep the foam sheet in its loopedshape. In other words, in the foam filling member, the foam sheet can bekept in the looped shape by the fixing member. Hence, the foam sheet canbe held stably, while being kept in its looped shape, without increasingthe number of components. Accordingly, improved vibration suppressionand sound insulation can be provided.

Also, the present invention provides a foam filling member for formingfoam to fill up a space of a structure, which comprises a foam sheetformed from foamable material and formed in sheet form, and a fixingmember for fixing the foam sheet in the space of the structure, whereinthe foam sheet is formed in a looped shape so that an overlapped portionwhere portions of the foam sheet are overlapped with each other in athickness direction thereof, and wherein the fixing member comprises aretaining portion, extending through the overlapped portion in thethickness direction, for retaining the foam sheet, and a fixing portionfor fixing the foam sheet in the structure.

In this foam filling member, while the foam sheet is held in its loopedshape by allowing the retaining portion of the fixing member to passthrough the overlapped portion in the thickness direction, the foamsheet is fixed in the space of the structure by the fixing portion ofthe fixing member. In other words, in this foam filling member, the foamsheet can be kept in the looped shape by the fixing member. Hence, thefoam sheet can be held stably, while being kept in its looped shape,without increasing the number of components. Accordingly, improvedvibration suppression and sound insulation can be provided.

Also, the present invention provides a foam filling member for formingfoam to fill up a space of a structure, which comprises a foam sheetformed from foamable material and formed in sheet form, and a fixingmember for fixing the foam sheet in the space of the structure, whereinthe foam sheet is formed in a looped shape so that a confronted portionwhere both lengthwise end portions of the foam sheet are confronted witheach other, and wherein the fixing member comprises a retaining portion,extending through the each lengthwise end portion of the foam sheet inthe thickness direction, for retaining the foam sheet, and a fixingportion for fixing the foam sheet in the structure.

In this foam filling member, while the foam sheet is held in its loopedshape by allowing the retaining portion of the fixing member to passthrough the lengthwise end portions of the foam sheet in the thicknessdirection, the foam sheet is fixed in the space of the structure by thefixing portion of the fixing member. In other words, in this foamfilling member, the foam sheet can be kept in the looped shape by thefixing member. Hence, the foam sheet can be held stably, while beingkept in its looped shape, without increasing the number of components.Accordingly, improved vibration suppression and sound insulation can beprovided.

Also, the present invention provides a foam filling member for formingfoam to fill up a space of a structure, which comprises a foam sheetformed from foamable material and formed in sheet form, and a fixingmember for fixing the foam sheet in the space of the structure, whereinthe foam sheet is formed in a looped shape so that an opposed portionwhere both lengthwise end portions of the foam sheet are spaced apartfrom each other and arranged to be opposed to each other, and whereinthe fixing member comprises a retaining portion, extending through theeach lengthwise end portion of the foam sheet in the thicknessdirection, for retaining the foam sheet, and a fixing portion for fixingthe foam sheet in the structure.

In this foam filling member, while the foam sheet is held in its loopedshape by allowing the retaining portion of the fixing member to passthrough the lengthwise end portions of the foam sheet in the thicknessdirection, the foam sheet is fixed in the space of the structure by thefixing portion of the fixing member. In other words, in this foamfilling member, the foam sheet can be kept in the looped shape by thefixing member. Hence, the foam sheet can be held stably, while beingkept in its looped shape, without increasing the number of components.Accordingly, improved vibration suppression and sound insulation can beprovided.

Also, the present invention provides a foam filling member for formingfoam to fill up a space of a structure, which comprises a foam sheetformed from foamable material and formed in sheet form, wherein the foamsheet is formed in a looped shape so that an overlapped portion whereportions of the foam sheet are overlapped with each other, and wherein aretaining portion for holding the foam sheet in the looped shape isformed at the overlapped portion of the foam sheet.

In this foam filling member, the foam sheet can be held in its loopedshape by the retaining portion formed in the overlapped portion of thefoam sheet. Hence, the foam sheet can be held stably, while being keptin its looped shape, without increasing the number of components.Accordingly, improved vibration suppression and sound insulation can beprovided.

In the present invention, it is preferable that the foam sheet has aflexural modulus of 2-180 MPa.

Also, the present invention provides a foam filling member for formingfoam to fill up a space of a structure, which comprises a foam sheetformed from foamable material and formed in sheet form, and a fixingmember for fixing the foam sheet in the space of the structure, whereinthe foam sheet is held to the fixing member in a freely slidable manner.

In this foam filling member, the foam sheet can be slid with respect tothe fixing member in the state of being fixed in the space of thestructure by the fixing member. This can allow the foam sheet to bemoved to a desired fixing position by sliding the foam sheet withrespect to the fixing member, thus facilitating the assembling work. Inthe foam filling member of the present invention, it is preferable thatthe fixing member comprises a fixing portion for fixing the foam sheetin the structure, and the foam sheet is held by the fixing member insuch a manner as to be extended between one side and the other side withrespect to the fixing portion by sliding the foam sheet toward the oneside with respect to the fixing portion.

In this foam filling member, the foam sheet can be arranged to extendbetween one side and the other side with respect to the fixing portionby simply sliding the foam sheet toward the one side with respect to thefixing portion after the fixing portion of the fixing member is fixed inthe structure. This can provide the result that for example in the casewhere spaces of the structure lie on one side of the fixing portion andthe other side thereof, respectively, when the fixing portion is fixedin the structure, the foam sheet can be located to extend over thespaces easily. This construction can facilitate the assembling work, ascompared with the construction wherein the foam filling members areplaced in the spaces, respectively.

In the foam filling member of the present invention, it is preferablethat the foam sheet is parted in two directions intersecting with thesliding direction at a portion thereof located on the one side withrespect to the fixing portion.

In this foam filling member, when the foam sheet is slid toward the oneside with respect to the fixing portion, the portion of the foam sheetlocated on one side of the fixing portion can be slid along twodirections intersecting with the sliding direction. This can allow thefoam sheet to extend over a wide area of the space located on the oneside with respect to the fixing portion, thus providing improvedvibration suppression and sound insulation.

Also, in the foam filling member of the present invention, it ispreferable that the fixing member has a guide portion for guiding theportion of the foam sheet located on the one side with respect to thefixing portion so that when the foam sheet is slid toward the one sidewith respect to the fixing portion, the portion of the foam sheetlocated on the one side with respect to the fixing portion can be spreadapart in two directions intersecting with the sliding direction.

In this foam filling member, when the foam sheet is slid toward the oneside with respect to the fixing portion, the portion of the foam sheetlocated on the one side with respect to the fixing portion can be spreadin two directions intersecting with the sliding direction along theguide portion. This can allow the foam sheet to extend over a wide areaof the space located on the one side with respect to the fixing portion,thus facilitating the assembling work.

Also, in the foam filling member of the present invention, it ispreferable that the foam sheet is formed in a looped shape to form anoverlapped portion where portions of the foam sheet are overlapped witheach other, so that both end portions of the foam sheet are located onthe one side with respect to the fixing portion.

In this foam filling member, although a relatively small amount offoamable material is used for the foam sheet, since the foam sheet isshaped like a loop, a central portion of the foam sheet can lie over awide area of the space located on the other side with respect to thefixing portion and also both end portions of the foam sheet can beextended over a wide area of the space located on the one side withrespect to the fixing portion. Hence, an amount of foamable materialused can be reduced and cost cut can also be achieved.

Also, in the foam filling member of the present invention, it ispreferable that the fixing member has a stop which is engageable withthe overlapped portion to regulate a sliding movement of the foam sheetwhen slid toward the other side with respect to the fixing portion.

In this foam filling member, when an external force acting to the otherside with respect to the fixing portion acts on the foam sheet, the foamsheet can be prevented from being slid and dropped off from the fixingmember by the stop. Thus, since the foam sheet can be prevented frombeing dropped off from the fixing member during the assembling work, theassembling work can be facilitated.

Also, in the foam filling member of the present invention, it ispreferable that in the fixing portion, the fixing member is fixed to apartition wall to partition the space of structure into a first spaceand a second space in such a manner that the first space is located atthe one side with respect to the fixing portion and the second space islocated at the other side with respect to the fixing portion.

In this foam filling member, the foam sheet can be located to extend tothe first space and the second space by simply sliding the foam sheettoward the one side with respect to the fixing portion after the fixingportion of the fixing member is fixed in the structure. Thisconstruction can facilitate the assembling work, as compared with theconstruction wherein the foam filling members are placed in the firstspace and the second space, respectively.

DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front view showing the first embodiment of a foam fillingmember of the present invention,

FIG. 2 is a perspective view of the foam filling member shown in FIG. 1,

FIG. 3 is a process drawing of the first embodiment of the way offilling an internal space of a pillar of an automobile by using the foamfilling member shown in FIG. 1, (a) showing the step of placing the foamfilling member in the pillar, and (b) showing the step of filling theinterior space of the pillar with the foam produced by the foam fillingmember being foamed, cross-linked, and cured by the application of heat,

FIG. 4 is a front view showing the second embodiment of the foam fillingmember of the present, invention,

FIG. 5 is a cross-sectional view showing the state of the foam fillingmember shown in FIG. 4 being placed in the pillar,

FIG. 6 is a front view showing the third embodiment of the foam fillingmember of the present invention,

FIG. 7 is a cross-sectional view showing the state of the foam fillingmember shown in FIG. 6 being placed in the pillar,

FIG. 8 is a front view showing the fourth embodiment of the foam fillingmember of the present invention,

FIG. 9 is a cross-sectional view showing the state of the foam fillingmember shown in FIG. 8 being placed in the pillar,

FIG. 10 is a perspective view of the foam filling member of the fifthembodiment of the present invention, showing the state before engagementof incisions,

FIG. 11 is a perspective view of the foam filling member shown in FIG.10, showing the state after engagement of the incisions,

FIG. 12 is a process drawing of an embodiment of the way of filling aninternal space of a pillar of an automobile by using the foam fillingmember shown in FIG. 11, (a) showing the step of placing the foamfilling member in the pillar, and (b) showing the step of filling theinterior space of the pillar with the foam produced by the foam fillingmember being foamed, cross-linked, and cured by the application of heat,

FIG. 13 is a cross-sectional view showing dimensions of the pillar usedin the examples,

FIG. 14 is a perspective view showing the sixth embodiment of the foamfilling member of the present invention,

FIG. 15 is a perspective view of the foam sheet of the sixth embodiment,showing the state before engagement of incisions,

FIG. 16 is a perspective view of the foam sheet of the sixth embodiment,showing the state after engagement of the incisions,

FIG. 17 is a perspective view of a clip of the sixth embodiment,

FIG. 18 is an orthographic drawing of the clip of the sixth embodiment,(a) showing a front view thereof, (b) showing a plane view thereof, (c)showing a bottom view thereof, and (d) showing a right side viewthereof,

FIG. 19 is a perspective view of the foam filling member which is in thestate of the foam sheet being slid upwardly from the state shown in FIG.14,

FIG. 20 is a perspective view showing an embodiment of the way offilling the interior space of the pillar of the automobile with the foamfilling member of the sixth embodiment, and

FIG. 21 is a right side view of the foam filling member and the pillarshown in FIG. 20.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a front view showing the first embodiment of a foam fillingmember of the present invention. FIG. 2 is a perspective view of thefoam filling member shown in FIG. 1,

A foam filling member 1 shown in FIGS. 1 and 2 is used for forming foamto be filled in a structural interspace or an interior space of hollowstructure. The foam filling member 1 comprises a foam sheet 2, and aclip 3 which is a fixing member for fixing the foam sheet 2 in thestructural interspace or the interior space of hollow structure.

The foam sheet 2 in sheet form is formed of foaming material which isfoamed by heating (e.g. at about 120° C. to about 210° C.).

Known foamable polymer is used as the foaming material without anyparticular limitation. The foamable polymer used is not limited to anyparticular one. The foamable polymers that may be used include, forexample, resins, such as ethylene•vinyl acetate copolymer, polyethylene,polypropylene, polyester, polyvinyl butyral, polyvinyl chloride,polyamide, and polyketone, and rubbers, such as styrene-butadiene rubber(SBR), and polybutadiene rubber (BR). Preferably, ethylene•vinyl acetatecopolymer is used as the foaming material. The use of ethylene•vinylacetate copolymer can provide an increased foam ratio. At least one ortwo materials of foamable polymer can be properly selected from thesefoamable polymers.

For enhancement of the foaming and curing of the foamable polymer, forexample a cross-linking agent, a foaming agent, and, if necessary, afoam auxiliary agent, may be mixed further in the foaming material.

No particular limitation is imposed on the cross-linking agent, whilefor example a known radical forming agent that can be decomposed byheating to produce a free radical so as to form a cross-linking bondamong molecules or in an individual molecule is used as thecross-linking agent. To be more specific, the radical forming agentsthat may be used include, for example, organic peroxides, such asdicumyl peroxide,1,1-di-tertiary-butyl-peroxy-3,3,5-trimethyl-cyclohexane,2,5-dimethyl-2,5-di-tertiary-butyl-peroxyhexane,2,5-dimethyl-2,5-di-tertiary-butyl-peroxyhexane,1,3-bis(t-butyl-peroxy-isopropyl)benzene, tertiary-butyl-peroxyketone,and tertiary-butyl-peroxybenzoate.

When the foamable polymer is to be vulcanized, a known vulcanizing agentcan be used as the cross-linking agent. No particular limitation isimposed on such a vulcanizing agent. For example, sulfur, sulfurcompounds, selenium, magnesium oxide, lead oxide, zinc oxide,polyamines, oximes, nitroso compounds, resins, and ammonium salts can becited as the vulcanizing agent.

At least one or two materials of these cross-linking agents can beselectively used. No particular limitation is imposed on a mixing ratioof the cross-linking agent. For example, a mixing ratio of thecross-linking agent to the foamable polymer is in the range of 0.1-10parts by weight, or preferably in the range of 0.5-7 parts by weight.

When the vulcanizing agent is used, a vulcanization accelerator may beused in combination. Known vulcanization accelerators including, forexample, dithiocarbamic acids, thiazoles, guanidines, sulfenamides,thiurams, xanthogen acids, aldehyde ammonias, aldehyde amines, andthioureas, may be used. At least one or two materials of thesevulcanization accelerators may be selectively used. A mixing ratio ofthe vulcanization accelerator to the foamable polymer is in the range of0.1-5 parts by weight.

On the other hand, rather than the vulcanization accelerators, knownvulcanization retardants such as, for example, organic acids and amines,may be properly mixed, for the purpose of molding control.

Also, no particular limitation is imposed on the foaming agent. Forexample, known inorganic or organic foaming agents are used. Theinorganic foaming agents that may be used include, for example, ammoniumcarbonate, ammonium hydrogen carbonate, sodium hydrogen carbonate,ammonium nitrite, sodium borohydride, and azides.

The organic foaming agents that may be used include, for example, azocompounds, such as azodicarbonamide, barium azodicarboxylate,azobisisobutyronitrile, and azodicarboxylic amide, nitroso compounds,such as N,N′-dinitrosopentamethylenetetramine,N,N′-dimethyl-N,N′-dinitrosoterephthal amide, andtrinitrotrimethyltriamine, hydrazide compounds, such as4,4′-oxybis(benzenesulfonylhydrazide), paratoluene sulfonylhydrazide,diphenylsulfone-3,3′-disulfonylhydrazide, andallylbis(sulfonylhydrazide), semicarbazide compounds, such asp-toluilene sulfonylsemicarbazide, and4,4′-oxybis(benzenesulfonylsemicarbazide), alkane fluorides, such astrichloromonofluormethane, and dichloromonofluoromethane, and triazolecompounds, such as 5-morpholyl-1,2,3,4-thiatriazole.

Among these foaming agents, the one that is decomposed at a temperatureequal to or higher than a softening temperature of foamable polymer togenerate gas and is hardly foamed in the process of forming the foam, asmentioned later, is selected properly in accordance to the compositionthereof. The foaming agent that is foamed in a temperature range betweenabout 120° C. and about 210° C. is preferably used.

At least one or two materials of these foaming agents can be selectivelyused. No particular limitation is imposed on a mixing ratio of thefoaming agent. For example, a mixing ratio of the foaming agent to thefoamable polymer is in the range of 5-50 parts by weight, or preferablyin the range of 10-30 parts by weight, per 100 parts by weight offoamable polymer.

A quantity of foaming agent mixed is preferably in such a range that thefoam sheet 2 containing the foaming agent, when foamed, practicallygenerates a closed cell at about five to about twenty-five times, orpreferably about ten to about twenty times, the foam ratio that the foamsheet containing no foaming agent does. When an excessively smallquantity of foaming agent is mixed, the foam sheet 2 is not foamedsufficiently, while on the other hand, when an excessively largequantity of foaming agent is mixed, a resin drip of the foam obtained bythe foaming is caused to thereby produce a void in the foam, bothcausing filling loss.

No particular limitation is imposed on the foam auxiliary agent. Forexample, a known foam auxiliary agent may be selected properly inaccordance to the type of foaming agent used. To be more specific, forexample, urea compounds containing urea as a main component includingmetal oxides, such as zinc oxide, and lead oxide, higher fatty acids,such as salicylic acid, and stearic acid, or metal salts thereof can becited as the foam auxiliary agent. A metal salt of a higher fatty acidis preferably used.

At least one or two materials of these foam auxiliary agents can beselectively used. No particular limitation is imposed on a mixing ratioof the foam auxiliary agent. For example, a mixing ratio of the foamauxiliary agent to the foamable polymer is in the range of 1-20 parts byweight, or preferably in the range of 5-10 parts by weight, per 100parts by weight of foamable polymer.

Further, known additives including, for example, stabilizer, stiffener,filler, and softener and, if required, for example, plasticizer, ageresister, antioxidant, pigment, colorant, fungicide, and flameretardant, may be additionally mixed properly for intended purposes andapplications, within the range of having little influence on thephysical properties of the foam obtained.

The foam sheet 2 is produced in the following processes, for example.First, after the respective components cited above are mixed at a mixingratio mentioned above, the mixture is kneaded using a mixing roll, apressure kneader, and the like, to prepare the foaming material. Then,the resulting foaming material is continuously formed in sheet form bythe continuous molding using a press, a calendar roll, or the like or bythe extrusion using e.g. an extruder. Thereafter, the resulting sheet isprocessed into strips of a predetermined width to thereby produce thefoam sheet 2.

When the foam sheet 2 is in the form of strip, the foam sheet 2 can beadvantageously produced with improved production efficiency and atreduced costs by using the continuous molding.

The foam sheet 2 thus obtained is properly adjusted in thicknessaccording to the structure form, while it is general that it has athickness of 0.5-6.0 mm, or preferably 1.0-5.0 mm. When the foam sheet 2has a thickness of less than 0.5 mm, there is the possibility that thefoam sheet 2 cannot fill up the structural interspace or the interiorspace of hollow structure sufficiently. On the other hand, when the foamsheet 2 has a thickness of more than 6.0 mm, there is the possibilitythat it may be difficult to fit (insert) the foam sheet 2 in when thestructural interspace or the interior space of hollow structure isnarrow.

Also, the foam sheet 2 has a flexural modulus of 2-180 MPa, orpreferably 2-150 MPa. By setting the flexural modulus of the foam sheet2 within this range, adequate degree of flexibility and resilience aregiven to the foam sheet 2. When the foam sheet 2 has a flexural modulusof less than 2, there is the possibility that the foam sheet 2 may beslacked at the heating to incur failure in foam filling. On the otherhand, when the foam sheet 2 has a flexural modulus of more than 180, itmay increase in resilience so excessively that it may reduce inworkability when fitted in the structure.

The clip 3 is formed of rigid resin and molded in one piece by theinjection molding and the like. The clip 3 comprises a fixing portion 4for fixing the foam sheet 2 in the interior space 22, and a retainingportion for retaining the foam sheet 2. The fixing portion 4 and theretaining portion 5 are integrally combined with each other.

The fixing portion 4 comprises a base portion 6, inner retainingportions 7 and a supporting portion 9, both projecting from the baseportion 6, and outer retaining portions 8 projecting from the supportingportion 9 toward the inner retaining portions 7.

The base portion 6 is shaped like a generally rectangular plate toreceive the foam sheet 2. The inner retaining portions 7 are in the formof thin, flexible sheet strips, which are formed on one side of the baseportion 6 and project obliquely from both lengthwise ends of the baseportion 6 to slant outwardly with respect to a longitudinal direction ofthe base portion 6.

The supporting portion 9 is formed on the one side of the base portion6, projecting from a lengthwise center portion of the base portion 6 ina direction orthogonal to the longitudinal direction of the base portion6.

The outer retaining portions 8 are in the form of thin, flexible sheetstrips, which project obliquely from free ends of the supporting portion9 toward the base portion 6 to slant outwardly with respect to thelongitudinal direction of the base portion 6. As a result, free ends ofthe outer retaining portions 8 are arranged to confront each other atspaced locations from intermediate portions of the inner retainingportions 9.

The retaining portion 5 comprises insertion shafts 10 to project fromthe base portion 6 in a direction opposite to the projecting directionof the supporting portion 9, and head portions 11 provided at free endsof the insertion shafts 10. The insertion shafts 10 are in the form of apair of halves 10A, 10B to provide a radial resilient force. Thesehalves 10A, 10B are formed on the other side of the base portion 6,projecting from a lengthwise center portion of the base portion 6 to adirection orthogonal to the longitudinal direction of the base portion6. The halves 10A, 10B are arranged to confront each other at spacedlocations in the longitudinal direction of the base portion 6.

The head portions 11 at the free ends of the insertion shafts 10 (thehalves 10A, 10B) are formed to protrude outwardly from peripheries theinsertion shafts 10.

Then, the foam filling member 1 is shaped like a loop (in an endlessform) by bending round the strip-like foam sheet 2 to form an overlappedportion 12 at which both lengthwise end portions of the foam sheet 2 areoverlapped with and confront each other in the thickness direction.Then, the insertion shafts 10 of the clip 3 are inserted in theoverlapped portion 12 to pass through it inwardly from outside of thelooped portion in the thickness direction, so that the head portions 11project inwardly thereof.

As a result, the overlapped portion 12 of the strip-like foam sheet 2 isheld in sandwich relation between the base portion 6 of the clip 3 andthe head portions 11 by the retaining portion 5, whereby the foam sheet2 is kept in its looped shape.

The foam filling member 1 thus formed is fixed in an interspace ofstructure or an interior space of hollow structure by inserting thesupporting portion 9 through the structure to hold the structure insandwich relation between the inner retaining portions 7 and the outerretaining portions 8 and, then, is heated to a foaming temperature (e.g.about 120° C. to about 210° C.). Then, the foam filling member 1 isfoamed and thereby the space is filled up without leaving any spacetherein. Hence, this foam filling member 1 is applicable as foam fillingmembers of a variety of industrial fields, including, for example,vibration-proof material, noise insulation material, dust-proofmaterial, heat insulating material, cushioning material, and watershutoff material, for the purposes of damping, noise reduction, dustcontrol, heat insulation, shock-absorbing, and water tight, withoutbeing limited to any particular ones.

In addition, this foam filling member 1 can provide the result that thefoam sheet 2 can be fixed in the space of structure by the fixingportion 4, while being kept in its looped shape by inserting theretaining portion 5 of the clip 3 through the overlapped portion 12 inthe thickness direction. Specifically, according to this foam fillingmember 1, since the clip 3 can serve to not only fix the foam fillingmember 1 to the structure but also keep the foam sheet 2 in its loopedshape, there is no need to use an additional member for keeping the foamsheet 2 in its looped shape. Hence, the foam sheet 2 can be held stably,while being kept in its looped shape, without any need to increase thenumber of components. Accordingly, improved vibration suppression andsound insulation can be provided.

To be more specific, when this foam filling member 1 is used for fillinga hollow structure such as, for example, an interior space of a pillarof a vehicle by foaming the foam sheet, vibrations and noises of avehicle engine or hissing sounds or fluttering sounds of the vehicle canbe effectively prevented from being transmitted to the vehicle interiorby the foam produced by foaming the foam sheet.

Next, a method of filling up the interior space of the pillar of thevehicle using this foam filling member 1 will be explained withreference to FIG. 3.

In this method, the foam sheet 2 is formed in a looped shapecorresponding to a size of an interior space 22 of a pillar 21 to befilled and, then, the insertion shafts 10 of the retaining portion 5 isinserted through the overlapped portion 12, whereby the foam sheet 2 isheld in place and kept in its looped shape corresponding in size to theinterior space 22 by the retaining portion 5 of the clip 3.

Then, the foam filling member 1 is placed in the interior space of thepillar 21, as shown in FIG. 3( a). The pillar 21 comprises an innerpanel 24 of a generally concave form in the cross-sectional view and anouter panel 25 of a generally concave form in the cross-sectional view.When the foam filling member 1 is set in the interior space of thepillar 21, the foam filling member 1 is fixed in the inner panel 24,first.

When the foam filling member 1 is fixed in the inner panel 24, thesupporting portion 9 of the fixing portion 4 is inserted in a fixinghole 26 formed at a predetermined location of the inner panel 24 frominside of the inner panel 24 (on a side thereof opposite to the outerpanel 25) toward outside of the same, while the outer retaining portions8 are elastically bent against resiliency of the outer retainingportions 8 to come close to the supporting portion 9. Then, the outerretaining portion 8 and the supporting portion 9 are both exposed fromthe outer surface of the fixing hole 26.

Then, the outer retaining portions 8 are restored to original state tobe away from the supporting portion 9 by their resiliency and are putinto elastic contact with the outer surface of the inner panel 24. Onthe other hand, when the supporting portion 9 is put in the state ofbeing inserted through the fixing hole 26, the inner retaining portions7 are put into elastic contact with the inner surface of the inner panel24. In other words, with the supporting portion 9 inserted in the fixinghole 26, the inner panel 24 is held in sandwich relation between theinner retaining portions 7 and the outer retaining portions 8 at alocation close to the fixing hole 26. The fixing portion 4 of the clip 3is fixed in the inner panel 24 in this manner.

Thereafter, the inner panel 24 in which the foam filling member 1 isfixed and the outer panel 25 are confronted with each other at theirflange portions at both ends thereof and joined to each other bywelding. As a result of this, the foam filling member 1 is fixed in theinterior space 22 of the pillar 21 formed to have a closed crosssection.

Then, after an inside surface of the pillar 21 is subjected to arust-proof treatment, the foam filling member 1 is foamed, cross-linked,and cured by heating (at e.g. 110-190° C.) in a subsequent process suchas, for example, a drying line process at the baking finish, to therebyproduce the foam 23, whereby the interior space 22 of the pillar 21 isfilled up with the foam 23, leaving no space therein, as shown in FIG.3( b).

The shape, location, arrangement orientation, arrangement number, etc.of foams 23 are properly selected in accordance with the shape, size,etc, of the pillar 21. To be more specific, the pillar 21 serves as afront pillar, a side pillar, or a rear pillar of a vehicle body.

It is preferable that the foam 23 has a density (weight (g) offoam/volume (cm³) of foam) of e.g. 0.04-0.2 g/cm³, or preferably0.05-0.1 g/cm³. Also, it is preferable that the foaming material isfoamed at a foam ratio of five to twenty-five times, or preferably tento twenty times, to obtain the foam 23.

In this foam filling member 1, the foam sheet 2 can be previously keptin its looped shape corresponding in size to the interior space 22 ofthe pillar 21 by the clip 3. This can allow the foam sheet 2 to beplaced stably in the interior space 22, with the size best suited to theinterior space 22 of the pillar 21. This can prevent displacement of thefoam sheet 2 so that the foam sheet 2 of a size best suited to theinterior space 22 can be reliably foamed without losing the looped shapeof the foam sheet 2. Hence, the interior space 22 can be filled up withthe foam 23 surely and reliably, leaving no space therein.

FIG. 4 is a front view showing the second embodiment of the foam fillingmember of the present invention, and FIG. 5 is a cross-sectional viewshowing the state of the foam filling member shown in FIG. 4 beingplaced in the pillar. In FIGS. 4 and 5, like reference numerals refer tocorresponding parts described above, while the explanation thereon isomitted.

In the foam filling member 1 of the first embodiment, the foam sheet 2is formed in a looped shape to form an overlapped portion 12 at whichboth lengthwise end portions of the foam sheet 2 are overlapped with andconfront each other in the thickness direction and, then, the insertionshafts 10 of the clip 3 are inserted in the overlapped portion 12 topass through it in the thickness direction, whereby the foam sheet 2 isheld in a looped shape by the clip 3. Alternatively, the foam sheet 2can be held in the looped shape by the clip 3 without forming theoverlapped portion 12, as shown in the second embodiment shown in FIG.4, for example. In the second embodiment, the foam sheet 2 is shapedlike a loop to form a confronted portion 15 where both lengthwise endsof the foam sheet 2 are opposed to and confronted with each other, andalso halves 10A, 10B of the insertion shafts 10 of the clip 3 areextended through the lengthwise end portions of the foam sheet 2 in thethickness direction, whereby the foam sheet 2 can be kept in the loopedshape by the clip 3.

Specifically, the foam filling member 1 shown in FIG. 4 is shaped like aloop (in an endless form) by bending round the strip-like foam sheet 2to form a confronted portion 15 at which both lengthwise ends of thefoam sheet 2 are opposed to and confronted to each other. Then, thehalves 10A, 10B of the insertion shafts 10 of the clip 3 are inserted inthe lengthwise end portions of the foam sheet 2 confronted to eachother, to pass through them inwardly from outside of the looped portionin the thickness direction, so that the head portions 11 of the halves10A, 10B project inwardly thereof.

As a result, the strip-like foam sheet 2 is held in sandwich relationbetween the base portion 6 and the head portions 11 of the clip 3 at thelengthwise end portions thereof with retaining by the retaining portion5, whereby the foam sheet 2 is kept in its looped shape.

The foam filling member 1 of the second embodiment thus formed is alsofixed in the interspace of structure or the interior space of hollowstructure by inserting the supporting portion 9 through the structure tohold the structure in sandwich relation between the inner retainingportions 7 and the outer retaining portions 8 and, then, is heated to afoaming temperature (e.g. about 120° C. to about 210° C.). Then, thefoam filling member 1 is foamed and thereby the space is filled upwithout leaving any space therein. Hence, this foam filling member 1 isalso applicable as foam filling members of a variety of industrialfields, including, for example, vibration-proof material, noiseinsulation material, dust-proof material, heat insulating material,cushioning material, and water shutoff material, for their intendedpurposes, as mentioned above.

In addition, this foam filling member 1 can provide the result that thefoam sheet 2 can be fixed in the space of structure by the fixingportion 4, while being kept in its looped shape by inserting theretaining portion 5 of the clip 3 through the lengthwise end portions inthe thickness direction. Specifically, according to this foam fillingmember 1, since the clip 3 can serve to not only fix the foam fillingmember 1 to the structure but also keep the foam sheet 2 in its loopedshape, there is no need to use an additional member for keeping the foamsheet 2 in its looped shape. Hence, the foam sheet 2 can be held stably,while being kept in its looped shape, without increasing the number ofcomponents. Accordingly, improved vibration suppression and soundinsulation can be provided.

To be more specific, for example, the foam sheet 2 is formed in a loopedshape corresponding to a size of the interior space 22 of the pillar 21to be filled, using this foam filling member 1, and, then, the halves10A, 10B of the insertion shafts 10 of the retaining portion 5 areinserted through the lengthwise end portions of the foam sheet 2, asshown in FIG. 5. Thereafter, the foam filling member 1 is placed in theinterior space of the pillar 21 in the same manner as above. Then, thefoam filling member 1 is foamed, cross-linked, and cured by heating (ate.g. 110-190° C.) in a subsequent process, such as, for example, thedrying line process at the baking finish, to thereby produce the foam.This can produce the result that the interior space 22 of the pillar 21can be filled up with the foam obtained, leaving no space therein, as isthe case with above.

FIG. 6 is a front view showing the third embodiment of the foam fillingmember of the present invention, and FIG. 7 is a cross-sectional viewshowing the state of the foam filling member shown in FIG. 6 beingplaced in the pillar. In FIGS. 6 and 7, like reference numerals refer tocorresponding parts described above, while the explanation thereon isomitted.

As shown in the third embodiment of FIG. 6, for example, the foam sheet2 is formed in a looped shape to form an opposed portion 16 at whichboth lengthwise end portions of the foam sheet 2 are spaced apart fromand arranged to be opposed to each other and, then, halves 10A, 10B ofthe insertion shafts 10 of the clip 3 are extended through thelengthwise end portions of the foam sheet 2 in the thickness direction,whereby the foam sheet 2 is held in a looped shape by the clip 3.

Specifically, the foam filling member 1 shown in FIG. 6 is shaped like aloop (in an endless form) by bending round the strip-like foam sheet 2to form the opposed portion 16 at which the both lengthwise ends of thefoam sheet 2 are spaced apart from and arranged to be opposed to eachother. Then, the halves 10A, 10B of the insertion shafts 10 of the clip3 are inserted in the lengthwise end portions of the foam sheet 2arranged to be opposed to each other, to pass through them inwardly fromoutside of the looped portion in the thickness direction, so that thehead portions 11 of the halves 10A, 10B project inwardly thereof.

As a result, the strip-like foam sheet 2 is held in sandwich relationbetween the base portion 6 and the head portions 11 of the clip 3 at thelengthwise end portions thereof with retaining by the retaining portion5, whereby the foam sheet 2 is kept in its looped shape.

The foam filling member 1 of the third embodiment thus formed is alsofixed in the interspace of structure or the interior space of hollowstructure by inserting the supporting portion 9 through the structure tohold the structure in sandwich relation between the inner retainingportions 7 and the outer retaining portions 8 and, then, is heated to afoaming temperature (e.g. about 120° C. to about 210° C.). Then, thefoam filling member 1 is foamed and thereby the space is filled upwithout leaving any space therein. Hence, this foam filling member 1 isalso applicable as foam filling members of a variety of industrialfields, including, for example, vibration-proof material, noiseinsulation material, dust-proof material, heat insulating material,cushioning material, and water shutoff material, as is the case withabove.

In addition, this foam filling member 1 can provide the result that thefoam sheet 2 can be fixed in the space of structure by the fixingportion 4, while being kept in its looped shape by inserting theretaining portion 5 of the clip 3 through the lengthwise end portions ofthe foam sheet 2 in the thickness direction. Specifically, according tothis foam filling member 1, since the clip 3 can serve to not only fixthe foam filling member 1 to the structure but also keep the foam sheet2 in its looped shape, there is no need to use an additional member forkeeping the foam sheet 2 in its looped shape. Hence, the foam sheet 2can be held stably, while being kept in its looped shape, withoutincreasing the number of components. Accordingly, improved vibrationsuppression and sound insulation can be provided.

To be more specific, for example, the foam sheet 2 is formed in a loopedshape corresponding to a size of the interior space 22 of the pillar 21to be filled, using this foam filling member 1, and, then, the halves10A, 10B of the insertion shafts 10 of the retaining portion 5 areinserted through the lengthwise end portions of the foam sheet 2, asshown in FIG. 6. Thereafter, the foam filling member 1 is placed in theinterior space of the pillar 21 in the same manner as above. Then, thefoam filling member 1 is foamed, cross-linked, and cured by heating (ate.g. 110-190° C.) in a subsequent process, such as, for example, thedrying line process at the baking finish, to thereby produce the foam.This can produce the result that the interior space 22 of the pillar 21can be filled up with the foam obtained, leaving no space therein, as isthe case with above.

FIG. 8 is a front view showing the fourth embodiment of the foam fillingmember of the present invention, and FIG. 9 is a cross-sectional viewshowing the state of the foam filling member shown in FIG. 8 beingplaced in the pillar. In FIGS. 8 and 9, like reference numerals refer tocorresponding parts described above, while the explanation thereon isomitted.

As shown in the fourth embodiment of FIG. 8, for example, the retainingportion 5 of the clip 3 is formed in U-like shape in cross-section,combined with the base portion 6. In this embodiment also, theoverlapped portion 12 of the foam sheet 2 can be held in sandwichrelation in the thickness direction by such a retaining portion 5, tokeep the foam sheet 2 in its looped shape by the clip 3.

Specifically, the retaining portion 5 of the clip 3 in the foam fillingmember 1 shown in FIG. 8 is not provided with the insertion shafts 10and their head portions 11. As a substitute for there, the foam fillingmember 1 is provided with a side wall 17 shaped like a generallyrectangular plate which projects from one end of the base portion 6 withrespect to a direction orthogonal to the longitudinal direction of thebase portion 6 in a direction opposite to the projecting direction ofthe supporting portion 9, and a top wall 18 shaped like a generallyrectangular plate which extends from an upper end of the side wall 17 toconfront the base portion 6 at a spaced interval. The side wall 17 andthe top wall 18 are combined integrally with each other. Further, a pawlportion 19 of a generally triangular cross-section projecting toward thebase portion 6 is provided at a free end of the top wall 18 on the sidethereof confronting the base portion 6.

Specifically, the foam filling member 1 is shaped like a loop by bendinground the strip-like foam sheet 2 to form the overlapped portion 12 atwhich the both lengthwise ends of the foam sheet 2 are overlapped withand opposed to each other in the thickness direction. Then, theretaining portion 5 is fitted onto the overlapped portion 12 along thewidthwise direction of the foam sheet 2 to hold the overlapped portion12 in sandwich relation between the pawl portion 9 at the top wall 18and the base portion 6 in the thickness direction.

As a result, the foam sheet 2 is held in sandwich relation between thebase portion 6 and the top wall 18 of the clip 3 at the overlappedportion 12 thereof with retaining by the retaining portion 5, wherebythe foam sheet 2 is kept in its looped shape.

The foam filling member 1 of the fourth embodiment thus formed is alsofixed in the interspace of structure or the interior space of hollowstructure by the fixing portion 4 by inserting the supporting portion 9through the structure to hold the structure in sandwich relation betweenthe inner retaining portions 7 and the outer retaining portions 8 and,then, is heated to a foaming temperature (e.g. about 120° C. to about210° C.). Then, the foam filling member 1 is foamed and thereby thespace is filled up without leaving any space therein. Hence, this foamfilling member 1 is also applicable as foam filling members of a varietyof industrial fields, including, for example, vibration-proof material,noise insulation material, dust-proof material, heat insulatingmaterial, cushioning material, and water shutoff material, as is thecase with above.

In addition, this foam filling member 1 can provide the result that thefoam sheet 2 can be fixed in the space of structure by the fixingportion 4, while being kept in its looped shape, by holding theoverlapped portion 12 of the foam sheet 2 in sandwich relation in thethickness direction by the retaining portion 5 of the clip 3.Specifically, according to this foam filling member 1, since the clip 3can serve to not only fix the foam filling member 1 to the structure butalso keep the foam sheet 2 in its looped shape, there is no need to usean additional member for keeping the foam sheet 2 in its looped shape.Hence, the foam sheet 2 can be held stably, while being kept in itslooped shape, without increasing the number of components. Accordingly,improved vibration suppression and sound insulation can be provided.

To be more specific, for example, the foam sheet 2 is formed in a loopedshape corresponding to a size of the interior space 22 of the pillar 21to be filled, using this foam filling member 1, as shown in FIG. 9, and,then, the overlapped portion 12 of the foam sheet 2 is held in sandwichrelation from the thickness direction by the retaining portion 5.Thereafter, the foam filling member 1 is placed in the interior space ofthe pillar 21 in the same manner as above. Then, the foam filling member1 is foamed, cross-linked, and cured by heating (at e.g. 110-190° C.) ina subsequent process, such as, for example, the drying line process atthe baking finish, to thereby produce the foam. This can produce theresult that the interior space 22 of the pillar 21 can be filled up withthe foam obtained, leaving no space therein, as is the case with above.

FIG. 10 is a perspective view of the foam filling member of the fifthembodiment of the present invention, showing the state before engagementof incisions, and FIG. 11 is a perspective view of the foam fillingmember shown in FIG. 10, showing the state after engagement of theincisions.

Although the embodiment wherein the foam sheet 2 is kept in its loopedshape by the retaining portion 5 of the clip 3 retaining the overlappedportion 12 of the foam sheet 2 have been described above, the need touse the retaining portion 5 of the clip 3 for holding the foam sheet 2can be eliminated by provision of an engaging portion 13, serving as theretaining portion, in the foam sheet 2 itself, as the foam fillingmember 1 shown in the fifth embodiment of FIGS. 10 and 11.

Specifically, as shown in FIG. 10, the foam sheet 2 is provided, at bothlengthwise end portions thereof, with incisions 14 which cut in the foamsheet 2 partway along a widthwise direction thereof (a directionorthogonal to the longitudinal direction) from mutually widthwiseopposite sides. The portions of the foam sheet 2 where these incisions14 are formed serve as the engaging portions 13.

The foam filling member 1 is shaped like a loop (in an endless form) bybending round the strip-like foam sheet 2 to form an overlapped portion(an intersecting portion) 12 where both lengthwise ends of the foamsheet 2 are overlapped with each other at the intersecting position inthe same manner as above, first. Then, the incisions 14 formed in theoverlapped portion 12 are engaged into each other, to form the foamsheet into the loop, as shown in FIG. 11.

As a result of this, the foam sheet 2 is fixed by the incisions 14 inthe overlapped portion 12 being engaged with each other and thus is keptin its looped shape.

Then, the foam filling member 1 thus formed is put into press-contactwith the structure by the resilient force of the foam sheet 2, to befixed in the interspace of structure or the interior space of hollowstructure and, then, is heated to a foaming temperature (e.g. about 120°C. to about 210° C.). Then, the foam filling member 1 is foamed andthereby the space is filled up without leaving any space therein. Hence,this foam filling member 1 is also applicable as foam filling members ofa variety of industrial fields, including, for example, vibration-proofmaterial, noise insulation material, dust-proof material, heatinsulating material, cushioning material, and water shutoff material,for the purposes of damping, noise reduction, dust control, heatinsulation, shock-absorbing, and water tight, without being limited toany particular ones.

In this foam filling member 1, the foam sheet 2 can be kept in itslooped shape by the engaging portions 13 formed in the overlappedportions 12 of the foam sheet 2. There is no need to use an additionalmember for keeping the foam sheet 2 in its looped shape. Hence, the foamsheet 2 can be held stably, while being kept in its looped shape,without increasing the number of components. Accordingly, improvedvibration suppression and sound insulation can be provided.

When this foam filling member 1 is used for filling up the hollowstructure such as, for example, the interior space of the pillar of thevehicle by foaming the foam sheet, vibrations and noises of a vehicleengine or hissing sounds or fluttering sounds of the vehicle can beeffectively prevented from being transmitted to the vehicle interior bythe foam produced by foaming the foam sheet.

Next, a method of filling up the interior space of the pillar of thevehicle will be explained with reference to FIG. 12. In FIG. 12, likereference numerals refer to corresponding parts to those of theembodiment illustrated above, while the explanation thereon is omitted.

In this method, the foam sheet 2 is formed in a looped shapecorresponding to a size of an interior space 22 of a pillar 21 to befilled and then the incisions 14 are engaged with each other at theoverlapped portion (the intersecting portion) 12, whereby the foam sheet2 is kept in its looped shape corresponding to the size of the interiorspace 22.

Then, the foam filling member 1 is placed in the interior space 22 ofthe pillar 21, as shown in FIG. 12( a).

When the foam filling member 1 is placed in the interior space 22 of thepillar 21, the foam sheet 2 is put in press-contact with the insidesurface of the pillar 21 by its resilient force so that it can be fixedin the interior space 22 of a closed cross section defined by joiningtogether the inner panel 24 and the outer panel 25 by welding.

Then, after the inside surface of the pillar 21 is subjected to arust-proof treatment, the foam filling member 1 is foamed, cross-linked,and cured by heating (at e.g. 110-190° C.) in a subsequent process suchas, for example, the drying line process at the baking finish, tothereby produce the foam 23, whereby the interior space 22 of the pillar21 is filled up with the foam 23, leaving no space therein, as shown inFIG. 12( b).

In this foam filling member 1, the foam sheet 2 can be previously keptin its looped shape corresponding in size to the interior space 22 ofthe pillar 21 by the engaging portions 13 provided in the foam sheet 2in itself. This can allow the foam sheet 2 to be placed stably in theinterior space 22, with the size best suited to the interior space 22 ofthe pillar 21. This can prevent displacement of the foam sheet 2 so thatthe foam sheet 2 of a size best suited to the interior space 22 can bereliably foamed without losing the looped shape of the foam sheet 2.Hence, the interior space 22 can be filled up with the foam 23 surelyand reliably, leaving no space therein.

Although the embodiment wherein the engaging portion 13 is formed by theincisions 14 cut in partway along its entire width at the overlappedportion 12 has been described above, as long as the engaging portion 13has the configuration that can allow the foam sheet 2 to be fixed in theoverlapped portion 12 of the foam sheet 2, the engaging portion 13 isnot limited to the one illustrated above. For example, the foam sheet 2may have the configuration at both lengthwise end portions thereof thata deeper incision 14 is formed at one lateral end portion of the foamsheet 2, while on the other hand, no incision 14 is formed at the otherlateral end portion of the foam sheet 2. Alternatively, the foam sheet 2may have a number of mutually engageable incisions 14 formed at the bothlengthwise end portions thereof.

FIG. 14 is a perspective view showing the sixth embodiment of the foamfilling member of the present invention. In the explanation on FIG. 14,a right near side is defined as a front side, a left far side is definedas a rear side, a left near side is defined as a left side, and a rightfar side is defined as a right side (the same applies to FIG. 17).

In FIG. 14, this foam filling member 1 is used for forming the foam tobe filled in the interspace of structure or in the interior space ofhollow structure. The foam filling member 1 comprises the foam sheet 2,and the clip 3 serving as the fixing member for fixing the foam sheet 2in the interspace of structure or in the interior space of hollowstructure.

FIG. 15 is a perspective view of the foam sheet 2 of the sixthembodiment, showing the state before engagement of incisions, and FIG.16 is a perspective view of the foam sheet 2 of the sixth embodiment,showing the state after engagement of the incisions,

The foam sheet 2 is the same as the one mentioned above. The foam sheet2 is formed of foamable material which is foamed by heating (at e.g.about 120° C. to about 210° C.) and is shaped in an elongate sheet form.

The foam sheet 2 of the sixth embodiment has in general a thickness of0.5-6.0 mm, or preferably 1.5-3.5 mm.

As shown in FIG. 15, the foam sheet 2 of the sixth embodiment isprovided, at both lengthwise end portions thereof where the overlappedportion 12 is formed, with incisions 14 which cut in the foam sheet 2partway along a widthwise direction thereof (a direction orthogonal tothe longitudinal direction) from mutually widthwise opposite sides, asis the case with the foam sheet 2 of the fifth embodiment. The portionsof the foam sheet 2 where these incisions 14 are formed serve as theengaging portions 13.

The foam filling member 1 is shaped like a loop by bending round thefoam sheet 2 to form an overlapped portion (an intersecting portion) 12where both lengthwise ends of the foam sheet 2 are overlapped with eachother at the intersecting position, first. Then, the incisions 14 formedin the overlapped portion 12 are engaged in each other, as shown in FIG.16. As a result of this, the foam sheet 2 is fixed by the incisions 14in the overlapped portion 12 being engaged with each other and thus iskept in its looped shape. When the incisions 14 of the foam sheet 2 areput in engagement with each other, a looped portion 31 is formed on thecenter side of the foam sheet 2 with respect to the overlapped portion12, while free end portions 32 are formed on the both-ends side of thefoam sheet 2 with respect to the overlapped portion 12.

Although the embodiment wherein the engaging portion 13 is formed by theincisions 14 cut in partway along the widthwise direction at theoverlapped portion 12 has been described above, as long as the engagingportion 13 has the configuration that can allow the foam sheet 2 to befixed in the overlapped portion 12 of the foam sheet 2, the engagingportion 13 is not limited to the one illustrated above, as is the casewith the foam sheet 2 of the fifth embodiment. For example, the foamsheet 2 may have the configuration at both lengthwise end portionsthereof that a deeper incision 14 is formed at one lateral end portionof the foam sheet 2, while on the other hand, no incision 14 is formedat the other lateral end portion of the foam sheet 2. Alternatively, thefoam sheet 2 may have a number of mutually engageable incisions 14formed at the both lengthwise end portions thereof.

FIG. 17 is a perspective view of a clip of the sixth embodiment, andFIG. 18 is an orthographic drawing of the clip of the sixth embodiment,(a) showing a front view thereof, (b) showing a plane view thereof, (c)showing a bottom view thereof, and (d) showing a right side viewthereof.

In FIGS. 17 and 18, the clip 3 is formed of rigid resin and molded inone piece to have a symmetrical appearance by the injection molding andthe like. The clip 3 comprises a fixing portion 4 for fixing the foamsheet 2 in an interspace of structure or an interior space of hollowstructure, and a retaining portion 5 for retaining the foam sheet 2. Thefixing portion 4 and the retaining portion 5 are integrally combinedwith each other.

The fixing portion 4 comprises a base portion 36, inner retainingportions 37 and a supporting portion 39, both projecting from the baseportion 36, and outer retaining portions 38 projecting from thesupporting portion 39 in a direction confronting the inner retainingportions 37.

The base portion 36 is shaped like a generally rectangular plate whichextends laterally. The inner retaining portions 37 are in the form ofthin, flexible sheet strips which are formed to project obliquelydownwardly from both lengthwise ends of the base portion 36 on the topside thereof to slant outwardly with respect to a longitudinal directionof the base portion 36. The supporting portion 39 is formed to projectoutwardly in the longitudinal direction of the base portion 36 from bothlengthwise ends of the base portion 36 on the bottom side thereof. Theouter retaining portions 38 are in the form of thin, flexible sheetstrips which project obliquely upwardly from free ends of the supportingportion 39 toward the base portion 36 to slant outwardly in thelongitudinal direction of the base portion 36. As a result, free ends ofthe inner retaining portions 37 are arranged to confront intermediateportions of the outer retaining portions 38 at spaced locationsrespectively.

The retaining portion 5 comprises a holding portion 40 of a generally Ushape, both ends of which are connected to the two supporting portions39, respectively, a front holding portion 41 extending between frontends of the two supporting portions 39, and a rear holding portion 42extending between rear ends of the two supporting portions 39. Whenviewed from top, predetermined spaces (e.g. substantially equal tothickness of the foam sheet 2) are defined between the front holdingportion 41 and a front surface of the base portion 36 and between therear holding portion 42 and a rear surface of the base portion 36,respectively.

The holding portion 40 comprises a left side plate portion 43 and aright side plate portion 44 which extend downwardly from the twosupporting portions 39, respectively, and a bottom plate portion 45connecting between lower ends of the left and right side plates 43, 44.The left side plate portion 43 and the right side plate portion 44 has,on their surfaces confronting each other, lugs 46 projecting inwardlywith respect to a confronting direction from portions thereof at aroundvertical center portions thereof. Each lug 46 is in the form of a thin,flexible strip having a generally triangular shape as viewed from topwhich becomes gradually narrowed toward the confronting direction. Thelugs 46 are spaced apart from each other with a predetermined spacedefined between their tip ends.

This foam filling member 1 is shaped like a loop by bending round thestrip-like foam sheet 2 to form the overlapped portion 12 where bothlengthwise end portions of the foam sheet 2 are overlapped with in thethickness direction. Then, the overlapped portion 12 is placed in agenerally rectangular space framed by the holding portion 40 and thefixing portion 4 of the clip 3. Then, one free end portion 32 of thefoam sheet 2 is held in sandwich relation between the front holdingportion 41 and the front surface of the base portion 36 so that it canbe held in a freely slidable manner and also the other free end portion32 of the foam sheet 2 is held in sandwich relation between the rearholding portion 42 and the rear surface of the base portion 36 so thatit can be held in a freely slidable manner (Cf. FIG. 14).

As shown in FIG. 14, in the foam filling member 1, the overlappedportion 12 of the foam sheet 2 is placed to be in the space definedbetween the bottom plate portion 45 and the lugs 46 of the holdingportion 40 of the clip 3. This arrangement can provide the result thatwhen the foam sheet 2 slides downwardly, the bottom plate portion 45 ofthe clip 3 is brought into engagement with the overlapped portion 12 ofthe foam sheet 2, thus serving as a stop for regulating the slide of thefoam sheet 2.

When the foam sheet 2 slides upwardly from the state shown in FIG. 14,the one free end portion 32 of the foam sheet 2 slides upwardly, passingthrough the space between the front holding portion 41 and the frontsurface of the base portion 36, while also the other free end portion 32of the foam sheet 2 slides upwardly, passing through the space betweenthe rear holding portion 42 and the back surface of the base portion 36.Resultantly, the overlapped portion 12 of the foam sheet 2 moves overeach lug 46 of the clip 3 and goes into the space between the fixingportion 4 and the lugs 46, followed by abutment with lower edges of thebase portion 36, as shown in FIG. 19.

At this time, the one free end portion 32 of the foam sheet 2 slidestoward the front side, while the other free end portion 32 of the foamsheet 2 slides toward the rear side. The two free end portions 32 of thefoam sheet 2 are parted in two directions intersecting with the slidingdirection, so that when the foam sheet 2 is slid upwardly, therespective free end portions 32 of the foam sheet 2 slide along the twodirections intersecting with the sliding direction.

The base portion 36 of the clip 3 has lugs 47, serving as guideportions, formed on the front and rear surfaces thereof, respectively,two lugs 47 for each surface. Each lug 47 has a generally triangularshape, as viewed from side elevation, having a predetermined width withrespect to the lateral direction. The two lugs 47 formed on the frontsurface of the base portion 36 are spaced from each other at spacedlocations with respect to the lateral direction. These lugs 47 are putin sliding contact with both lateral edges of the one free end portion32 of the foam sheet 2 sliding through the space between the frontholding portion 41 and the front surface of the base portion 36. The twolugs 47 formed on the rear surface of the base portion 36 are spacedfrom each other at spaced locations with respect to the lateraldirection. These lugs 47 are put in sliding contact with both lateraledges of the other free end portion 32 of the foam sheet 2 slidingthrough the space between the rear holding portion 42 and the rearsurface of the base portion 36. This can provide the result that whenthe foam sheet 2 is slid upwardly, the free end portions 32 thereof areguided to each lug 47 to spread apart in the two directions intersectingwith the sliding direction.

The foam filling member 1 of the sixth embodiment thus formed can befixed in the interspace of structure or the interior space of hollowstructure by inserting the fixing portion 4 in the structure to hold thestructure in sandwich relation between the inner retaining portion 37and the outer retaining portion 38. Also, the foam sheet 2 can beextended to two spaces formed on one side and on the other side withrespect to the structure on which the fixing portion 4 is mounted bysliding the foam sheet 2 toward the fixing portion 4.

When heated to a foaming temperature (e.g. about 120° C. to about 210°C.), the foam sheet 2 is foamed and thereby the two spaces where thefoam sheet 2 is placed are filled up without leaving any space therein.Hence, this foam filling member 1 of the sixth embodiment is alsoapplicable as foam filling members of a variety of industrial fields,including, for example, vibration-proof material, noise insulationmaterial, dust-proof material, heat insulating material, cushioningmaterial, and water shutoff material, for the purposes of damping, noisereduction, dust control, heat insulation, shock-absorbing, and watertight, without being limited to any particular ones.

To be more specific, when this foam filling member 1 of the sixthembodiment is used for filling up the hollow structure such as, forexample, an interior space of the pillar of the vehicle by foaming thefoam sheet 2, vibrations and noises of a vehicle engine or hissingsounds or fluttering sounds of the vehicle can be effectively preventedfrom being transmitted to the vehicle interior by the foam produced byfoaming the foam sheet 2.

FIG. 20 is a perspective view showing an embodiment of the way of filingup the interior space of the pillar of the vehicle with the foam fillingmember of the sixth embodiment, and FIG. 21 is a right side view of thefoam filling member and the pillar shown in FIG. 20.

Next, a method of filling up the interior space 22 of the pillar 21 ofthe vehicle with the foam filling member 1 of the sixth embodiment willbe explained with reference to FIGS. 20 and 21. In FIGS. 20 and 21, formaking the foam filling visually understandable, only an area of thepillar 21 near the foam filling member 1 mounting portion of the pillar21 is shown and the rest of the areas of the pillar 21 is omitted.

This foam filling member 1 is applied to e.g. a pillar 21 having adouble structure comprising a cylindrical inner panel 51, and an outerpanel 52 located outside of the inner panel 51 and defining apredetermined space between the inner panel 51 and the outer panel 52.Such a pillar 21 comprises a first space 22A formed between the innerpanel 51 and the outer panel 52, and a second space 22B formed in theinterior of the inner panel 51. A part of the inner panel 51 confrontingthe outer panel 52 serves as a partition wall 53 between the first space22A and the second space 22B.

In this method, the foam sheet 2 is shaped like a loop corresponding toa size of an interior space 22 (the first space 22A and the second space22B) of a pillar 21 to be filled, first. Then, as shown in FIG. 14, theoverlapped portion 12 of the foam sheet 2 is placed in the space betweenthe bottom plate portion 45 and lugs 46 of the holding portion 40 of theclip 3. Also, the one free end portion 32 of the foam sheet 2 is held insandwich relation between the front holding portion 41 and the frontsurface of the base portion 36 so that it can be held in a freelyslidable manner, while the other free end portion 32 of the foam sheet 2is held in sandwich relation between the rear holding portion 42 and therear surface of the base portion 36 so that it can be held in a freelyslidable manner.

Then, the foam filling member 1 is placed in the interior space 22 ofthe pillar 21. When the foam filling member 1 is placed in the interiorspace 22 of the pillar 21, the foam filling member 1 is fixed in theinner panel 51, first. Specifically, the fixing portion 4 of the clip 3is inserted in a fixing hole 54 formed in the partition wall 53 of theinner panel 51 from inside of the inner panel 51 toward outside (theouter panel 52 side) of the same, while the free end portions of theinner retaining portions 37 are elastically bent against resiliency ofthe inner retaining portions 37 to come close to the base portion 36.Then, the inner retaining portions 37 and the top portion of the baseportion 36 are both exposed from outer of the fixing hole 54. Then, theinner retaining portions 37 are restored to original state so that thefree end portions are away from the base portion 36 by the resiliencyand are put into elastic contact with the outer surface of the innerpanel 51. On the other hand, when the base portion 36 is put in thestate of being inserted through the fixing hole 54, the outer retainingportions 38 are put into elastic contact with the inner surface of theinner panel 51. In other words, with the base portion 36 inserted in thefixing hole 54, the inner panel 51 is held in sandwich relation betweenthe inner retaining portions 37 and the outer retaining portions 38 at alocation close to the fixing hole 54. The fixing portion 4 of the clip 3is fixed in the inner panel 51 in this manner.

Thereafter, the foam sheet 2 is slid upwardly. Then, the overlappedportion 12 of the foam sheet 2 moves over each lug 46 of the clip 3 andgoes into the space between the fixing portion 4 and the lugs 46,followed by abutment with the lower edges of the base portion 36, asshown in FIGS. 20 and 21. As a result, the one free end portion 32 ofthe foam sheet 2 slides upwardly, passing through the space between thefront holding portion 41 and the front surface of the base portion 36,while also the other free end portion 32 of the foam sheet 2 slidesupwardly, passing through the space between the rear holding portion 42and the rear surface of the base portion 36. At this time, as depictedby a chain double dashed line of FIG. 19, the two free end portions 32of the foam sheet 2 are guided by the lugs 47 of the clip 3 to be splitapart slantwise in a V-like shape. Then, when the foam sheet 2 is slidfurther, the free end portions 32 are brought into contact with theouter panel 52 and then are curved so that their tips come near thelooped portion 31, as depicted by a solid line of FIG. 19.

Thus, each free end portion 32 of the foam sheet 2 is located in thefirst space 22A located on one side with respect to the fixing portion 4so that they can be spread apart in mutually opposite directions, andthe looped portion 31 of the foam sheet 2 is located in the second space22B located on the other side with respect to the fixing portion 4. Inthis state, the foam sheet 2 is in the state of extending between thefirst space 22A and the second space 22B.

The inner panel 51 may be formed in a cylindrical shape, for example, byjoining together two segments. This inner panel 51 may be formed in sucha manner that after the foam filling member 1 is fixedly fitted in thefixing hole 54 formed in one segment, the one segment and the othersegment are arranged opposite to each other and joined together bywelding.

The outer panel 52 may be joined directly to an outside surface of theinner panel 51, for example, by welding and the like, or mayalternatively be positioned to cover the entirety of the inner panel 51,with the entirety of its inside surface spaced apart from the entiretyof an outside surface of the inner panel 51.

Then, after the inside surface of the pillar 21 is subjected to therust-proof treatment, the foam filling member 1 is foamed, cross-linked,and cured by heating (at e.g. 110-190° C.) in a subsequent process suchas, for example, the drying line process at the baking finish, tothereby produce the foam, whereby the first space 22A and the secondspace 22B of the pillar 21 is filled up with the foam, leaving no spacetherein.

In this foam filling member 1 of the sixth embodiment, the foam sheet 2can be slid with respect to the clip 3 in the state of being fixed inthe space of the structure, such as the pillar 21, by the clip 3. Thiscan allow the foam sheet 2 to be moved to a desired fixing position bysliding the foam sheet 2 with respect to the clip 3, thus facilitatingthe assembling work.

Also, in this foam filling member 1 of the sixth embodiment, the foamsheet 2 can be arranged to extend between the first space 22A and thesecond space 22B by simply sliding the foam sheet 2 toward the one side(upper side) with respect to the fixing portion 4 after the fixingportion 4 of the clip 3 is fixed in the structure, such as the pillar21. This arrangement can facilitate the assembling work, as comparedwith the arrangement wherein the foam filling members are placed in thefirst space 22A and the second space 22B, respectively.

Further, in this foam filling member 1 of the sixth embodiment, when thefoam sheet 2 is slid toward the one side (toward the first space 22A)with respect to the fixing portion 4, the free end portions 32 of thefoam sheet 2 are slid along two directions intersecting with the slidingdirection. This can allow the foam sheet 2 to go into the space (firstspace 22A) located on the one side with respect to the fixing portion 4over the wide range, thus providing improved vibration suppression andsound insulation.

In addition, in this foam filling member 1 of the sixth embodiment, whenthe foam sheet 2 is slid toward the one side (toward the first space22A) with respect to the fixing portion 4, the free end portions 32 ofthe foam sheet 2 can be spread apart in two directions intersecting withthe sliding direction along the lugs (guide portion) 47 of the clip 3.This can allow the foam sheet 2 to go into the space (first space 22A)located on the one side with respect to the fixing portion 4 over thewide range, thus facilitating the assembling work.

Further, in this foam filling member 1 of the sixth embodiment, althougha relatively small amount of foamable material can be used for the foamsheet 2, since the foam sheet 2 is shaped like a loop, a central portionof the foam sheet 2 can lie over a wide area of the space (second space22B) located on the other side with respect to the fixing portion 4 andalso both end portions of the foam sheet 2 can go into the space (firstspace 22A) located on the one side with respect to the fixing portion 4over the wide range. Hence, an amount of foamable material used can bereduced and cost cut can also be achieved.

In this foam filling member 1, since the foam sheet 2 can be previouslykept in its looped shape corresponding in size to the interior space 22(first space 22A and second space 22B) of the pillar 21 by the clip 3,the foam sheet 2 can be placed stably in the interior space 22 of thepillar 21, with the size best suited to the interior space 22 of thepillar 21. This can prevent losing of the looped shape of the foam sheet2 caused by displacement of the foam sheet 2 and can also allow reliablefoaming of the foam sheet 2 with its size best suited to the interiorspace 22. Hence, the interior space 22 can be filled up with the foam 23surely and reliably, leaving no space therein.

Further, in this foam filling member 1 of the sixth embodiment, when anexternal force acting to the other side (downward) with respect to thefixing portion 4 acts on the foam sheet 2 during the assembling work,the foam sheet 2 can be prevented from being slid and dropped off fromthe clip 3 by the bottom plate portion (stop) 45. Thus, the foam sheet 2can be prevented from being dropped off from the clip 3 during theassembling work, thus facilitating the assembling work.

The foam filling member 1 of the sixth embodiment is not limited to thecontents of any one of the embodiments illustrated above. For example,as long as the foam filling member 1 is structured so that the foamsheet 2 can be held in a freely slidable manner with respect to the clip3, the foam sheet 2 may be formed in any other shape without beinglimited to the looped shape.

Also, the foam filling member 1 of the sixth embodiment is not limitedto the application to the pillar 21 having a double structure. The foamfilling member 1 may be used for forming the foam to fill up theinterior space of the pillar of a different shape. Also, it may be usedfor forming the foam to fill up the interspace of the other structurethan the pillar or the interior space of hollow structure.

Example

While in the following, the present invention will be described infurther detail with reference to Examples, the present invention is notlimited thereto.

1) Preparation of Foam Filling Member

After components of foamable polymer, crosslinking agent, and foamingagent were mixed in accordance with the blending prescription shown inFIG. 1, the mixture obtained was kneaded at a rotation speed of 20 min⁻¹at 110° C. using a mixing roll, to prepare foaming material. Then, thefoaming material was press molded for one minute at 110° C. and formedinto a sheet having thickness of 5 mm, using a hot press. The sheet wascut to strips of 175 mm long and 15 mm wide, to produce the foam sheetstrips of Examples 1-6. The flexural modulus of the foam sheet strips ofExamples are shown in TABLE 1.

Then, each foam sheet strip was shaped like a loop by bending the foamsheet to form an overlapped portion at which both lengthwise endportions of the foam sheet were overlapped with each other in thethickness direction. Then, the clip formed of nylon was inserted in theoverlapped portion, passing through it inwardly from outside of theendless portion in the thickness direction, to thereby produce the foamfilling members of Examples.

The foam filling members thus produced correspond to the foam fillingmember of the first embodiment illustrated above.

2) Fixing of Foam Filling Member to Pillar and Foaming of the Same

The foam filling member of each Example thus obtained was fixed in theinterior space of the pillar having a size shown in FIG. 13 via the clipand then was foamed to fill up the interior space.

To be more specific, the foam filling member of the each Example wasfixed to the inner panel via the clip, first. Then, after the outerpanel was laid on the inner panel, flanges of the inner panel and outerpanel provided at both ends were confronted with each other and joinedtogether by welding. The workability in mount of the foam fillingmembers of Examples on the pillars (easiness for mount of the foam sheeton the pillar against resilience) was evaluated. The results are shownin TABLE 1. In the evaluation, the mark ◯ indicates Excellent, and themark Δ indicates Ordinary.

Then, the pillars on which the foam filling members were mounted wereput in the oven for twenty minutes at 160° C., to foam the foam sheetsin the pillars. Then, the foam filling for the interior space of thepillar was evaluated by visual inspection. The results are shown inTABLE 1. In the evaluation, the mark ◯ indicates Excellent, and the markΔ indicates Ordinary.

TABLE 1 Material Name of article Manufacturer Ex. 1 Ex. 2 Ex. 3 Ex. 4Ex. 5 Ex. 6 Foamable EVA EVAFLEX DU PONT-MITSUI 100  — — — — — polymer*1 EV40LX POLYCHEMICALS EVA EVAFLEX DU PONT-MITSUI — 100  — — — — EV460POLYCHEMICALS EVA ULTRASEN 543 Tosoh — — 100  — — — EVA ULTRASEN 511FTosoh — — — 100 — — EVA ULTRASEN 760 Tosoh — — — — 100  — PE SUMIKASENSumitomo Mitsui — — — — — 100 G210 Polyolefin Cross-linking DCP *2PARCUMYL NOF Corporation 5  5  5  5 5  5 agent D-40MBK Foaming agentOBSH *3 CELMIKE SX SANKYO KASEI 20  20 20  20 20   20 Flexural modulus(MPa) 2 39 80 150 1 200 Foam filling ◯ ◯ ◯ ◯ Δ *4 ◯ Workability ofmounting to pillar ◯ ◯ ◯ ◯ ◯ Δ *5 *1 EVA (ethylene-vinyl acetatecopolymer), PE (Low-density polyethylene) EVAFLEX EV40LX (Available fromDU PONT-MITSUI POLYCHEMICALS Co., Ltd., MFR2.0, Contains 41 mass %polyvinyl acetate) EVAFLEX EV460 (Available from DU PONT-MITSUIPOLYCHEMICALS Co., Ltd., MFR2.5, Contains 19 mass % polyvinyl acetate)ULTRASEN 543 (Available from Tosoh Corporation, MFR1.3, Contains 10 mass% polyvinyl acetate) ULTRASEN 511F (Available from Tosoh Corporation,MFR2.5, Contains 6 mass % polyvinyl acetate) ULTRASEN 760 (Availablefrom Tosoh Corporation, MFR70, Contains 42 mass % polyvinyl acetate)SUMIKASEN G210 (Available from Sumitomo Mitsui Polyolefin) *2 OBSH:4,4′-oxybis(benzenesulfonyl hydrazide), Available from EIWA KASEI KOGYO,Neosrene HM806P, Contains 80 weight % OBSH, 20 weight % EPDM) *3 DCP:Dicumylperoxide, Available from NOF Corporation, PARCUMYL D-40MBK,Contains 40 weight % dicumylperoxide, 60 weight % silica + EPDM) *4 Foamlayer was slacked, so that foam filling failure was partly incurred. *5Flexural modulus was so high that workability of mounting to pillar wasdown.

While the illustrative embodiments of the present invention are providedin the above description, such is for illustrative purpose only and itis not to be construed restrictively. Modification and variation of thepresent invention that will be obvious to those skilled in the art is tobe covered by the following claims.

1. A foam filling member for forming foam to fill up a space of astructure, which comprises a foam sheet formed from foamable materialand formed in sheet form, wherein the foam sheet is formed in a loopedshape so that an overlapped portion, where portions of the foam sheetare overlapped with each other, is formed and wherein a retainingportion for holding the foam sheet in the looped shape is formed at theoverlapped portion of the foam sheet.